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Technical How to cut small slots in fender well?

Discussion in 'The Hokey Ass Message Board' started by Sporty45, Jun 25, 2019.

  1. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    I had to do some repairs to my fender wells on my 47 Olds and will need to replace the caged fender nuts. I have the hole drilled for them, but don't know how to cut nice small slots for the ears on the nuts. The slots are .100" wide x 1/4" long. Anybody have a good way to do it? These are the kind of nuts I'm talking about.

    [​IMG]
     
  2. Casey Riley
    Joined: Jun 27, 2018
    Posts: 543

    Casey Riley
    Member
    from Minnesota

    If it was me, I would carefully use a dremmel with that little 1" cut off wheel. And then shape it with a Nicholsen round pointed swiss file #0
    [​IMG]
     
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  4. 49ratfink
    Joined: Feb 8, 2004
    Posts: 18,829

    49ratfink
    Member
    from California

    you have ears on your nuts? that paints an interesting visual.
     
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  5. Bandit Billy
    Joined: Sep 16, 2014
    Posts: 12,287

    Bandit Billy
    ALLIANCE MEMBER

    Make a pattern out of something non magnetic and use a plasma cutter. You will be done in a few minutes.
     
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  6. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    I already have die grinders, but they aren't always easy to control on small stuff like what I need. Maybe if I try a small radiac wheel first to kind of put a groove into the metal to guide the bit. Hmmm...
     
  7. F-ONE
    Joined: Mar 27, 2008
    Posts: 3,271

    F-ONE
    Member
    from Alabama

    Is that really the type you need?
    Do you have to have those "ears"?
    Would you better cutting those tabs off and riveting or welding (like a spot weld) those?
     
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  8. x2 :cool:
     
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  9. This is a 'micro' grinder, much easier to control plus you can get very small bits for it. Might be best to drill a series of holes then connect them. Building a drill guide fixture would be a huge help too if you have to do more than a few of them. If you have the bolt holes drilled, you could bolt the fixture into place.
     
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  10. 19Fordy
    Joined: May 17, 2003
    Posts: 8,027

    19Fordy
    Member

    Mark where you want the slot to be.
    Then drill a small hole on each end of the marked out slot.
    Then slice cut it with a small cut of wheel.

    QUESTION: If you know where you want the cage nuts to be located,
    why not cut off the tabs and weld the cage nuts in place. That way no water seeps in.
     
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  11. Terrible80
    Joined: Oct 1, 2010
    Posts: 785

    Terrible80
    Member

  12. Terrible80
    Joined: Oct 1, 2010
    Posts: 785

    Terrible80
    Member

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  13. Would a broach cutting tool/bit work? , they cut square holes. HRP
     
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  14. Use a rotary file and a Dremel tool. @.100 if you used a .125 rotary file you would be fine.
     
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  15. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    They are the type that are in there now, and I'm trying to keep the same thing in there. I have thought about just welding them, but would like to keep the original look. Just me I guess!
     
  16. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    The slots are pretty small. I'd actually have to cut past where I need it in order for the wheel to cut completely through the drilled holes. I guess I could just weld the groove that extends past the cut out slot afterwards.

    And I'm trying to keep it like original :D
     
  17. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

  18. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    I don't think there is one small enough. That idea is a good one though!
     
  19. saltflats
    Joined: Aug 14, 2007
    Posts: 12,594

    saltflats
    Member
    from Missouri

    Drill two holes at the end of where you want the slots then take a sharp chisel modified for the slot and cut out the center between the drilled holes.
     
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  20. papajohn
    Joined: Nov 2, 2006
    Posts: 896

    papajohn
    Member

    Sharpen a small screw driver, and bang it thru where you want the slot while someone backs it up with a hunk of 2x4
     
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  21. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    Good ideas here! This would be so much easier if it was just a piece of sheet metal on the bench, but twisting myself up under the wheel well to do this is a PIA! :eek:
     
  22. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    Well, I gave the small drill and file method a try and it worked out pretty good! I found a drill bit that measured .100" and drilled a couple holes at the end of the slot, then got my die grinder with a very small radiac wheel and scored most of the metal away between the drilled holes, then attacked it with a small file. One pic shows the rusted out piece of metal I used as a template. Sprayed the wheel wells with some epoxy primer and called it done.Thanks for tips guys :cool: IMG_20190626_101229125.jpg IMG_20190626_101545477.jpg IMG_20190626_101805132.jpg IMG_20190626_101844225.jpg IMG_20190626_104812242.jpg
     
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  23. Bert Kollar
    Joined: Jan 10, 2007
    Posts: 1,232

    Bert Kollar
    Member

    I would just cut the tabs off and spot weld them on
     
  24. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,168

    Sporty45
    Member

    Thanks, but I didn't want to do that :rolleyes:
     
  25. You did it about how I was thinking. Anything cut, drilled and stacked on like that, I like to use some of that black putty stuff (I forget the name) for windshields and firewall grommet/wire sealing. It doesn't dry up or wick out and can be painted right over, plus there are no voids to trap water.

    I picked that up from a neighbor who is a dent removal pro and when he has to drill holes to access the back sides, he uses the black stuff with the plugs to make 'em watertight and rustproof.
     
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